hi,

Could someone help me on how to reapir (or replace) a water tube that it is leaking under the intake, this is a metal tube and I do not know how it is attached to the motor. there is a good picture of this at the following site: http://leckemby.net/windstar/windstar01.html
And the picture with the note under it that says "EGR Ports Exposed" shows the tube that I am refering to. this tube runs from right to left under the intake and the leak is just at the union with the post (at the right of the picture) the one that is connected to the motor.
Any help I will apprciate.

Regards

Jaime

You may have to replace the lower (aluminum) intake to deal with this issue. That steel tube, I believe, is just pressed into the aluminum lower intake. I don't know of anyone that has easily separated these two pieces. ... especially if there is extensive corrosion.

On a workbench, perhaps using a torch ... things will be different. But you may find that you need a new lower in the end... I would go ahead and price one, just in case.
I have replaced the lower intake gasket on my '99. Not rocket science ... but it needs to be done "by the book" ... using a torque wrench. (A lot a engine cleaning should be the first step. Avoid gettin coolant or dirt into the crankcase). Those bolts require only 7 - 8 foot lbs of torque, IIRC.

If you remove the lower intake manifold......you WILL get some coolant into the crankase.....right when you lift it up and break the seal at the lower intake manifold gaskets......it is unavoidable...
For this reason, you MUST, as the instructions say, change the engine oil BEFORE starting up the engine.

Also, EVERY time the lower intake manifold is removed, you MUST replace the lower intake manifold gaskets with new ones.
I would buy the replacement gaskets from FORD so that you are sure to get ones with the improvements that FORD has made to them, to improve the reliability.
They say to use a small drop of sealant at the corners where the end seal and head gaskets meet.....make SURE to use a sealant that is "SENSOR SAFE".

My '96 3.8L may be different, but I did replace the Crossover pipe when I worked on my lower intake manifold gaskets, the old part was fine, but I did not know for sure, until I removed it....and I wanted to have the part on hand in case the old one was bad.
The connection on the passenger side, same side as water pump, is part of the replaceable tube.
The part on the driver side, is pressed into the lower intake manifold, as already stated.

On mine, the hose that connects to the driver's side, is the heater hose.
The heater hose has one of those "quick connect" connectors on it.....which is not so quick if you do not have the special tool to release the nylon clips.
You can get the tool at Autozone, on the loaner program.
Is it possible that your leak is coming from that connector?......
Mine fell apart, even when I used the correct tool to remove it.......(although mine is somewhat older than yours), and I did not have the correct size to replace it.....(I think mine is 3/4" and I had 5/8") so I cut the quick connect off and pushed the hose onto the nipple, and used a regular hose clamp.
I did not find much information on the quick connector.......but did find it in the Aerostar repair information.

hi,

Could someone help me on how to reapir (or replace) a water tube that it is leaking under the intake, this is a metal tube and I do not know how it is attached to the motor. there is a good picture of this at the following site: http://leckemby.net/windstar/windstar01.html
And the picture with the note under it that says "EGR Ports Exposed" shows the tube that I am refering to. this tube runs from right to left under the intake and the leak is just at the union with the post (at the right of the picture) the one that is connected to the motor.
Any help I will apprciate.

Regards

Jaime

The pipe is easy to fix. After you get to it following the removal instructions on the leckemby site. You disconect the hose at the left rear and the bypass hose from the reservoir. Then remove the 2 screws holding the pipe down. Pull the pipe upwards and it will dislodge from the intake manafold. It is just connected with an "O" ring. Do any repairs needed (mine had a pin hole in it and a solder fix took care of it). Use a new "O"ring and put everything back together.

Regards
Justlost

Justlost,
That's good info, thanks. Guess I didn't try hard enough.

Was this an internal or external leak that you were trying to fix?